Fiber drafting and blending system



July 29, 1969 J. R. WHITEHURST FIBER DRAFTING AND BLENDING SYSTEM 5Sheets-Sheet 1 Filed May 4, 1967 INVENTORZ AORNEYS july 29, 1969 J. R.WHITEHURST 3,457,595

FIBER DRAFTING AND BLENDING SYSTEM 5 Sheets-Sheet 2 Filed May 4, 1967INVENTOR;

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ATTORNEYS July 29, 1969 J. R. WHITEHURST FIBER DRAFTING AND BLENDINGSYSTEM Filed May 4, 1967 5 Sheets-Sheet 5 I NVENTOR.

ATTORNEYS July 29, 1969 J. R. WHITEHURST FIBER DRAFTING AND BLENDINGSYSTEM 5 Sheets-Sheet 4.

Filed May 4, 1967 90% elk-v INVENTOR.

ATTORNEYS July 29, 1969 J. R. WHITEHURST FIBER DRAFTING AND BLENDINGSYSTEM 5 Sheets-Sheet 5 Filed May 4 1967 mT I H E w H w DRv J A BYbdm,Wlwwl ATTORNEYS United States Patent 3,457,596 FIBER DRAFTING ANDBLENDING SYSTEM Joe R. Whitehurst, Kings Mountain, NC, assignor, bymesne assignments, to The Warner & Swasey Company, Cleveland, Ohio, acorporation of Ohio Continuation-impart of application Ser. No. 565,580,July 15, 1966. This application May 4, 1967, Ser. No. 636,169

Int. Cl. D01h 5/00 U.S. Cl. 19243 4 Claims ABSTRACT OF THE DISCLOSURE Arow of side-by-side primary drafting units are arranged to deliverrespective textile webs of different types of fibers to a commonconveyor means where they are superimposed and directed to a commonprocessing machine or secondary drafting unit, and wherein all thedrafting units and the conveyor means are driven by a common primemover, with means interconnecting the primary drafting units and theprime mover in such a manner as to permit correlating the speed ofdelivery rolls of different primary drafting units relative to eachother to obtain substantially the same rate of delivery of the webstherefrom to compensate for inherent differences in the delivery rate ofdifferent types of fibers.

This application is a continuation-in-part of my copending US.application Ser. No. 565,580, filed July 15, 1966, and entitled Methodand Apparatus for Blending Textile Fibers.

This invention relates to the art of blending masses of textile fibersby drafting the same wherein the masses may differ from one another byhaving fibers of different lengths and/or kinds or, in the case ofcotton fibers, they may come from different bales or from differentareas of the world. As regards the kinds of fibers, they may differ asto physical characteristics and may include animal fibers, natural orman-made cellulosic fibers, mineral fibers and/or synthetic fibers;i.e., any textile fibers capable of being drafted and blended accordingto the instant invention.

Textile machinery capable of drafting simultaneously and independently anumber of separate masses of like textile fibers as webs andsuperimposing said webs and delivering the same to a common windingmachine or other processing machine is generally known. Ribbon lap andsliver lap machines are typical of such machinery. US. Patent No.3,013,313 of Catling et al., issued Dec. 19, 1961, also isrepresentative of various patents embodying this principle.

Until recently; i.e., prior to the development of the method andapparatus disclosed and claimed in my said copending application, theblending of masses of different types of fibers effectively on a singlemachine by drafting was impracticable because each primary or breakerdrafting unit in a row must be capable of individual adjustment toaccommodate staple fibers of different average lengths at differenttimes, to impart different amounts of draft to different masses offibers at different times, and to compensate for well known inherentdifferences in the delivery rate of different types of fibers consequentto differences in the traction or slickness between the fibers and therolls of respective drafting units so as to impart substantially thesame delivery rate to the webs emerging from all the primary draftingunits in a row, All of these conditions are satisfied to a substantialdegree in the ap paratus of my said copending application which is pri--marily directed to the use of primary or breaker drafting, units havingfluted intermeshing delivery rolls generally known as metallic rolls.

Patented July 29, 1969 Usually, in a metallic roll type of draftingunit, all the pairs of drafting rolls are metallic; i.e., they are ofthe intermeshing fluted type. Many drafting units, which may be termedas cushion roll type drafting units, are equipped with a smooth-faced orcushion top delivery roll and a fluted bottom delivery roll. At leastthe No. 2 top roll; i.e., the top roll immediately rearward of thedelivery rolls, of a cushion roll type drafting unit is also a cushionroll resting upon a fluted roll, and the remaining top rolls preferablyare metallic, but may be either metallic or cushion type rolls.

As is generally accepted, better processing results in utilizingintermeshing metallic drafting rolls where the stock being produced isof standard or relatively heavy weight. This is especially true withmost all synthetic fibers except the fine denier fibers, since theintermeshing fluted rolls permit obtaining the desired controlengagement of the fibers during the drafting thereof. Additionally, thedelivery rolls result in imparting desirable crimp to the syntheticfibers which aids in further processing thereof by enhancing thecohesiveness of the fibers relative to each other. On the other hand,where the stock being produced is of relatively light weight or is offine denier fibers or combed stock, it is accepted that cushion toprolls are most desirable, at least at the front portion of the draftingunit, for obtaining the proper engagement and control of the fibers.Thus, it is readily apparent that in a blending system it is mostdesirable, if not imperative, that the system lend itself for utilizingat any given time either or both types of drafting units in order toenable the system to properly produce any desired type of blend.

Some mills would prefer to use metallic roll drafting units but toeliminate the necessity for changing the extent of intermeshingrelationship of fluted delivery rolls to effect desired changes indelivery speed of primary drafting units of a blending system. Also,other mills, irrespective of whether or not metallic roll type units mayproduce a better quality product from the particular textile material tobe drafted, are Wedded to cushion roll type drafting units. Thus, theseadditional considerations point up the desirability of being able toutilize either type of drafting unit to satisfy customer requirements.

It is desirable to provide separate means for advancing the web fromeach of the successive primary drafting units to obtain the desiredtension draft in each individual web in accordance with the dictates ofthe characteristics of the fibers forming the same. Further, it isdesirable to advance the webs along the row of primary drafting unitsand to the common processing unit without affecting the tension draftbeing applied to the individual webs emerging from the primary draftingunits.

Therefore, it is an object of this invention to provide a fiber blendingsystem of the general type disclosed in said copending application, inwhich the primary or breaker drafting units in a row may include eitheror both the metallic roll type and the cushion roll type heretoforedescribed, with all the units being driven by a common prime mover, andwherein driving connections are so arranged between the prime mover andthe units that the speed of the delivery rolls of each primary draftingunit may be correlated relative to the speed of the delivery rolls ofanother unit or other units in the row to obtain substantially the samedelivery rate of the webs emergi therefrom, and wherein the webs areindividually tensioned and then superimposed and directed to a commonprocessing unit by conveyor means common to all the primary draftingunits and driven by said prime mover.

Another object is to provide a drafting system of the type lastdescribed wherein a pair of fluted calender rolls driven by theaforementioned prime mover is provided above the conveyor means andadjacent each primary drafting unit for individually advancing andcrimping each respective web and maintaining the same under optimumtension in its course from the delivery rolls to the conveyor means.

Some of the objects of the invention having been stated, other objectswill appear as the description proceeds when taken in connection withthe accompanying drawings, in which FIGURE 1 is a perspective view of apreferred arrangement of drawing frames or drafting units for draftingand blending textile fibers according to the present invention;

FIGURE 2 is an enlarged fragmentary and elevation taken substantiallyalong line 22 in FIGURE 1 and showing driving connections for rotatingthe primary calender rolls;

FIGURES 3 and 3A are, collectively, a somewhat schematic, enlarged, topplan view of the drafting and blending system shown in FIGURE 1 with thevarious drafting units thereof being uncovered for purposes of clairity;

FIGURE 4 is an enlarged front elevation of one of the drafting unitsshowing how the corresponding web is directed to the conveyor means andsuperimposed upon webs from preceding drafting units, and being takensubstantially along line 4-4 in FIGURE 3A;

FIGURE 4A is an enlarged detail of the mounting means for the flutedcalender rolls 120, 121 of FIGURE 4;

FIGURE 5 is an enlarged vertical sectional view taken transversely ofthe drafting rolls of the unit shown in FIGURE 4 and substantially alongline 55 in FIGURE 3A;

FIGURE 6 is an enlarged front elevation, partially in section, of thegearing shown in the right-hand portion of FIGURE 4; and

FIGURE 7 is a right-hand side elevation of the gearing shown in FIGURE 6with corresponding support brackets being shown in phantom lines.

Referring more specifically to the drawings, the preferred embodiment ofthe fiber drafting and blending apparatus of this invention comprises arow of a plurality of individual side-by-side primary drafting units,there preferably being three or more such primary drafting units, andfour of which are shown in FIGURE 1 and in combined FIGURES 3 and 3A,respectively, generally designated at I, II, III and IV. Fibers from theprimary drafting units are directed to a common processing machine orsecondary drafting unit V. Although all the drafting units I-V aredirectly interconnected and driven by a common prime mover embodied inan electric motor 10, each primary drafting unit may be self-containedto the extent that (a) each unit may draft a different type of fibrousmaterial than the others, (b) each unit may impart a different amount ofdraft to the fibrous material than the others, and (c) the weight perunit length of the material being received by and delivered from eachprimary drafting unit may be different from that of the other primarydrafting units. By directly interconnecting and driving all the primarydrafting units from a common prime mover, uniform output speed of fibersfrom the primary units is obtained with respect to each other, eventhough periods of acceleration and deceleration of the drafting unitsmay occur when starting and stopping the same.

As shown in FIGURES 1, 3 and 3A, a separate mass of textile fibers ortextile material is introduced into each primary drafting unit I-IV inthe form of a plurality of slivers S, such as card slivers, drawn from asuitable creel including supply cans C. Primary drafting units I-IVdeliver the textile material, in the form of respective thin, veil-like,broad, flat, fibrous primary webs W1, W2, W3, W4 onto respective curledguide plates 11 which curve downwardly and beneath themselves to invertthe respective webs and change their direction of movement by about 90as they are deposited upon a supporting means in the form of a primaryendless belt conveyor 12. The The upper run of conveyor 12. extendsalong the row of primary drafting units and below the level of thedelivery rolls thereof to be later described, and toward the secondarydrafting unit V. Thus, the webs are successively arranged into stackedor superimposed relationship to form, ultimately, a common multi-layeredor composite web W5.

Endless belt conveyor 12 is driven, in a manner to be later described,to direct the webs W1-W4 along the row of primary drafting units and todirect the composite web W5 onto the upper run of a secondary beltconveyor 14 which extends upwardly and forwardly at an angle to directthe composite web W5 into secondary drafting unit V.

A calendering and crimping device 15 is provided above primary conveyor12 and adjacent the discharge end of each curved plate 11 to aid inpreserving the relationship of the fibers in each respective primary webW1-W4 while effectively pulling and advancing the respective primary webtoward conveyor 12. Additionally, following the crimping and subsequentsuperimposing of the primary webs Wl-W4, and before the resultantcomposite web W5 enters the secondary drafting unit V, the composite webis compacted by means of a secondary calendering device 16. As shown,the secondary drafting unit V is arranged to blend and draft thecomposite web and deliver the same in the form of a web which may betaken up on a suitable roll, not shown, or which may be condensed into ablended sliver S (FIGURE 3A) and coiled into a can 20 for furtherprocessing.

Each drafting unit IV may comprise a plurality of sets of top and bottomdrafting rolls, there being four sets of such rolls provided for eachdrafting unit in this instance, indicated at 31-34 and 31'34',respectively. Rolls 31-34 are generally known as No. 4, No. 3, No. 2 andNo. 1 top rolls, respectively. The drafting rolls of all drafting unitsI-V may be arranged as shown in FIG- URES 4, 5 and 6, wherein portionsof drafting unit IV are shown.

As stated earlier, however, it is desirable that the blending system iscapable of accommodating either or both metallic roll type and cushionroll" type drafting units. Accordingly, the drafting units I-V may be ofeither or both types and, as shown in FIGURES 3 and 3A, for example,primary drafting units I, II and secondary unit V are each of themetallic roll type in which all the top rolls 31-34 are fluted and meshwith the respective bottom fluted rolls. On the other hand, primaryunits III, IV are shown as being of the cushion roll type in which allthe top rolls may be of the cushion type or, as shown and is moregenerally the case, in which the delivery or No. 1 top roll 34 and theNo. 2 top roll 33 are of the cushion type resting upon fluted bottomrolls; and the No. 3 and No. 4 top rolls 32, 31, respectively, arefluted metallic rolls meshing with the respective fluted bottom rolls32', 31' (see FIGURE 5).

An explanation as to the reasons why each of these two types of draftingunits has certain advantages over the other will now be given. Ametallic roll type drafting unit is desirable for drafting and producingstandard weight and heavy weight fibrous material of from 50 to 600grains per yard or heavier whose fibers are of standard or greatercoarseness (8 denier and more) because, even though the pressure appliedto fluted top rolls may be as little as 16 pounds (which is about 5percent of the pressure applied to cushion top rolls), the intermeshingflutes of metallic rolls, due to the bulk of the mass, grip suchmaterial very firmly so there is very little if any slippage of fibersbetween a pair of intermeshing fluted rolls. If such heavy weight andcoarse denier fibrous material is being drafted through a cushion rolltype drafting unit, the fibers in the core of the material will slip toa considerable extent relative to the outer fibers, even though apressure of 200 to 320 pounds or more is being applied to the topcushion roll. It is apparent that the relatively lighter weightingrequired on fluted rolls reduces the wear metallic intermeshing rolls.The later types of fibrous ma- I terials are not grasped as firmly by apair of metallic rolls because such rolls must not bottom against eachother and, therefore, a small clearance is maintained between the ridgesand valleys of the intermeshing flutes, which clearance is not filled bythe small mass and thus permits some slippage of the latter types offibrous materials between a pair of metallic intermeshing No. 1 or No. 2rolls of a metallic roll drafting unit.

Metallic No. 3 and No. 4 top and bottom rolls are desirable in a cushionroll drafting unit because of the greater weight of the stock, therelatively small amount of draft being imparted thereto, and therelatively slow linear speed of the stock passing through theseparticular rolls as compared to the stock passing through the frontdrafting zone and between the delivery or No. 1 and the No. 2 draftingrolls. Thus, the earlierdescribed advantages of metallic roll draftingare applicable in the rear drafting zones of a cushion roll draftingunit.

All the bottom drafting rolls of the drafting units are driven by theprime mover 10 in a manner to be later described, and all the topdrafting rolls are driven by contact with the textile material passingbetween the top and bottom drafting rolls. It is preferred that thefluted feed roll 31 of each primary drafting unit normally rests uponthe slivers passing over the respective bottom feed roll 31' so that thefeed rolls 31, 31 are in relatively deep intermeshing relationship upona relatively thin place in the textile material passing therebetween,thus advancing such thin place at a relatively faster than normal speed.Conversely, upon a relatively thick place in the textile materialpassing between feed rolls 31, 31', the intermeshing relationship of thefeed rolls 31, 31' is reduced so that the textile material is deliveredto the succeeding intermediate drafting rolls 23, 32' at a relativelyslower speed. Thus, the weight per unit of time of the material beingreceived by the intermediate drafting rolls 32, 32 is substantiallyuniform, although the material being received by feed rolls 31, 31 maybe of varying weight along its length. The feed rolls of the secondarydrafting unit should not be capable of performing the evening actionlast described because they must take up all the webs W1-W4 in compositeweb W5 at a constant linear speed during normal operation of the system.

With the important exception that all the drafting units I-V are drivenby a common prime mover, each primary drafting unit I-IV is arranged forindependent operation to the extent that the fibers being drafted byeach primary drafting unit may differ in one or more respects relativeto the fibers being drafted by another or other primary drafting units.As to the differences in relative slipperiness of different kinds offibers or slippage thereof relative to drafting rolls, tests have shownthat, in a typical drafting unit utilizing a set of delivery rollsrotating at a given speed, the delivery speed of separately drafteddifferent kinds of fibers varied from about 100 f.p.m. (feet per minute)to about 110 f.p.m. For example, a web formed only of Acrilan fibers(acrylic staple) issued from delivery rolls at about 100 f.p.m., a webformed only of Dacron fibers (polyester staple) issued from deliveryrolls at about 104 f.p.m., and a web formed only of cotton fibers issuedfrom delivery rolls at about 110 f.p.m. A blend of about 50 percentcotton fibers and about 50 percent synthetic fibers issued fromcorresponding delivery rolls at about 105 f.p.m. Further variation indelivery speed of the webs has also been experienced in changing fromone denier and/ or staple length to another. It is axiomatic that suchvariations in delivery speeds cannot be tolerated if the required weightper unit length and distribution of fibers are to be achieved in thecomposite web W5 and the resultant drafted material made therefrom.Conversely, if it is assumed that the fibers being drafted through eachprimary drafting unit I-IV are of a different kind than the fibers beingdrafted through the other drafting units, it may be necessary to pullthe webs W1-W4 from the respective units at slightly different speeds toallow for differences in cohesiveness of the fibers and stretchabilityof the different webs while providing for sufficient tension drafttherein.

For the purposes of this disclosure, reference to various types offibers, unless otherwise qualified, shall mean that the fibers in one ormore masses differ from those fibers in another or other masses withregard to average staple length, relative slipperiness of adjacentfibers, and/ or slippage of the fibers relative to the correspondingdrafting rolls, such that the roll spacing, the amount of draft effectedin the drafting zone between adjacent sets of drafting rolls, and/or thespeed of the delivery rolls 34, 34' required to effect a given deliveryspeed of the web at any one or more of the primary drafting units I-IVmust differ with respect to another or others of the primary draftingunits.

To provide for independent adjustment of the spacing of the draftingrolls of each drafting unit, the stepped bearings 36, 36' (Figure 6), inwhich opposite ends of each pair of top and bottom drafting rolls arejournaled, are supported in substantially U-shaped bearing blocks 37,there being a separate bearing block 37 supporting each end of each pairof top and bottom drafting rolls. The bearing blocks 37 at each side ofeach drafting unit are relatively adjustable on corresponding rollstands 40, suitably secured to the frame 41 of the correspondingdrafting unit. As shown in FIGURES 5 and 6, each roll stand 40 may beprovided with a longitudinal slot 43 in its upper bridging portionthrough which a screw 44 for each bearing block 37 extends for securingthe bearing blocks in the desired adjusted positions in accordance withthe staple length of the fibers in the particular mass being drafted bythe particulardrafting unit.

As heretofore stated, all the drafting units I-V are driven by primemover 10.

As shown, a common jack shaft 50 extends along the row of primarydrafting units I-IV and is drivingly connected to the front draftingrolls of each primary drafting unit by an individual transmission meansor gear train including a drive gear 51 fixed on shaft 50 and meshingwith one of a pair of change gears 53 (FIGURE 6). The other of thechange gears 53 engages a gear 54 fixed on one reduced end of thecorresponding bottom delivery drafting roll 34'. It is important to notethat the change gears 53 provide means for adjustably controlling thespeed of each pair of delivery rolls 34, 34' independently of the otherpairs of delivery rolls, as well as adjustably controlling the speed ofall the rolls of each respective primary drafting unit, even though allthe primary drafting units are driven by jack shaft 50.

The change gears 53 associated with each primary drafting unit arefixedly interconnected in axial relationship and are mounted on a stubshaft 58 adjustably secured to a pivoted bracket 59 whose lower portionis pivotally supported on jack shaft 50. Each pivoted bracket 59 isprovided with an arcuate slot 60 therein (FIGURE 7) penetrated by anadjustment screw 61 for adjustably securing the same to a standard 62.Each standard 62 is fixed upon the frame 41 of the corresponding primarydrafting unit. Jack shaft 50 is journaled in standards 62 and may extendthrough the roll stands 40 of primary drafting units I-IV so that it maybe positioned beneath and adjacent bottom delivery rolls 34', as ispreferred. If so desired, jack shaft 50 may be manufactured in shortsections with suitable couplings 64 (FIGURES 3 and 3A) interconnectingadjacent sections thereof at the junctures of adjacent primary draftingunits.

The end of jack shaft 50 adjacent secondary drafting unit V is connectedto the output side of a gear box 66 whose input side has a sprocketwheel 67 fixed thereon engaged by an endless sprocket chain 70. Sprocketchain 70 is also mounted on a sprocket wheel 71 fixed on a shaft 72connected by a train of gears 73 to the drafting rolls of secondarydrafting unit V. The drafting rolls of secondary drafting unit V areinterconnected, in a conventional manner, by the usual draft gearing andthe front bottom drafting roll 34 of secondary drafting unit V isconnected to electric motor or prime mover 10, preferably by means of anelectromagnetic clutch 76 which may be energized and deenergized in awell-known manner for starting and stopping secondary drafting unit Vand thus for starting and stopping the entire drafting and blendingsystem of the present invention.

The means for varying the amount of draft and transmitting rotation tothe intermediate and back drafting rolls of each primary drafting unitI-IV from the respective front or bottom delivery roll 34 may be similarto that disclosed in my said copending application. Accordingly, themeans for transmitting rotation from the bottom delivery roll 34 of eachprimary drafting unit to the intermediate and back drafting rolls willnot be described in detail, it being deemed sufficient to state thateach gear 54 is connected to one of the intermediate drafting rollsthrough a gear train including change gears 80, and the other end of thelatter intermediate bottom drafting roll is connected by a gear train 81to the other intermediate bottom drafting roll and to the bottom feedroll 31' of the corresponding drafting unit. Change gears 80 are securedin fixed axial relationship and mounted on a stub shaft 83 adjustable ina slotted bracket 84 (FIG- URE 7) to enable the use of change gears 80of different sizes for changing the relative speeds of the intermediatedrafting rolls 32, 32 and 33, 33' of each primary drafting unit andthereby to change the amount of draft effected by the correspondingdrafting unit without the necessity of changing the speed of deliveryrolls 34, 34'.

Any suitable means may be employed for applying yieldable downwardpressure to each end of each top drafting roll 31-34, such as is shownin United States Patents Nos. 2,412,357 and 3,143,772, for example. Suchpressure-applying means may include a separate springloaded plunger 90bearing against each bearing 36. The spring-loaded plungers at each sideof each drafting unit may be carried by supports 91 overlying thecorresponding bearings 36.

The enlarged portions of those bearings 36 (FIGURE which support anyintermediate and front top rolls 32, 33, 34 which are of the metallicfluted type (as is the case with respect to primary units I, II) bearagainst the respective bearings 36 therebeneath to ensure apredetermined depth of intermeshing relationship of the respective pairsof rolls, and thereby to prevent bottoming of the fluted rolls and toensure that the stock leaves each such pair of fluted rolls at aconstant linear speed relative to the peripheral speed of thecorresponding rolls. This is also true with respect to the feed rolls31, 31' of the secondary drafting unit V.

The endless belt conveyor 12, upon which webs W1- W4- are successivelysuperimposed, and the secondary or ramp belt conveyor 14 which conveysthe composite web W5 from conveyor 12 to secondary drafting unit V, aremounted on respective pairs of pulleys 100, 101; 102, 103 suitablyrotatably supported by the frames of adjacent drafting units. Adjacentpulleys 101, 102 of belt conveyors 12, 14 may be drivinglyinterconnected by a pair of sprocket wheels 105, 106 and aninterconnecting endless sprocket chain 107 at one end thereof (FIGURE3A). The other end of conveyor pulley 101 is connected to one of theoutput sides of gear box 66 by means of a pair of sprocket wheels 110,111 and an interconnecting endless sprocket chain 112, thus operativelyconnecting the conveyors 12, '14 to prime mover 10.

In order to maintain the upper runs of belt conveyors 12, 14 insubstantially straight condition during operation thereof, suitablesupport plates or platforms 115, 116 may be provided therefor. Platformmay be supported by cantilever arms 117 secured to and projectingoutwardly from the frames of adjacent primary drafting unils. Platform116 may be similarly supported by the frame of secondary drafting unitV.

The primary calendering devices 15 (see FIGURES and 4A) are provided toensure the desired degree of adjustment of the rate of travel of theprimary webs W1- W4, under the desired tension, from the respectiveprimary drafting units to the belt conveyor 12, especially whencushion-type top delivery drafting rolls are used. In this connection,space limitations and economy in manufacture dictate that the gears 5254(FIGURE 6) should be relatively small. The range of change gears, suchas gears 53, which may be used does not always permit the fineadjustment of tension draft needed for best results.

Therefore, as best shown in FIGURES 4 and 4A, each primary calenderingdevice comprises a pair of top and bottom fluted intermeshingcalendering rolls 120, 121 which may be of the same type as illustratedfeed rolls 31, 31' of each drafting unit. As will be later explained, itis important that the depth of intermeshing relationship of each pair ofprimary calender rolls 129, 121 is accurately controlled. Therefore,reduced opposite ends of rolls 120, 121 are rotatably mounted inrespective top and bottom bearings 120a, 121a (FIGURE 4A) mounted insubstantially U-shaped bearing stands 123. The bearings 120a bearagainst the bearings 1210. Various diameters of bearings 120a may beemployed to permit changing the depth of mesh of each top calender roll120 with the respective bottom roll 121 to impart the desired rate oftravel to each web Wl-W4 from the delivery rolls 34, 34' to conveyor'12. Bearings 120a may be engaged by suitable spring weighting devicesor spring pressure devices 125 mounted in the respective bearing stands123 so as to maintain the top calender rolls 120 in pressure engagementwith the primary fibrous webs passing between respective pairs ofcalender rolls 120, 121.

To aid in effectively directing each web onto belt conveyor 12 or ontoanother or other webs on the belt conveyor 12, as the case may be, thedischarge end of each curved plate 11 terminates closely adjacent thenip of the respective pair of primary calender rolls 120, 121, and,additionally, the calender rolls 120, 121 are arranged in angularpositions; i.e., an imaginary line extending through and perpendicularto the axes of the calender rolls 120, 121 extends at an acute anglewith respect to the forward direction of movement of the upper run ofbelt conveyor 12. Bearing stands 123 may be suitably secured tocorresponding cantilever arms 117 heretofore described (FIG- URES 3, 3A,4 and 5).

The bottom calender rolls 121 of the primary calendering devices 15 aredrivingly connected to a calender drive shaft by suitable gearing, notshown, in respective gear boxes 131 suitably secured to the respectivecantilever arms 117. Calender drive shaft 130 is common to all theprimary calendering units 15, is rotatably supported in gear boxes 131,and is driven by suitable driving connections with jack shaft 50, suchas are shown in FIGURE 2. Accordingly, the end of shaft 130 adjacent thefirst primary drafting unit I has a gear 133 fixed thereon which mesheswith an idler gear 134 suitably supported by the frame of drafting unitI and fixed in a axial relation to a pulley 135. Pulley 135 is engagedby an endless belt 136 which also engages a pulley 137 fixed on thecorresponding end of jack shaft 50. It is thus seen that prime mover 10is drivingly connected to the bottom rolls 121 of the primarycalcndering devices 15.

Prime mover 10 is also drivingly connected to a pair of smooth-facedcalender rolls 140 of secondary calendering device 16 by means of a pairof sprocket wheels 141, 142 and an interconnecting endless sprocketchain 143. Sprocket wheel 141 is fixed on one reduced end of thebottommost of the smooth-faced calender rolls 140, and sprocket wheel142 is arranged in fixed axial relation to sprocket wheel 111. Thecalender rolls 140 of secondary calendering device 16 may be mounted inthe same manner as rolls 120, 121 of the primary calendering devices 15and, therefore, a further description of the calendering device 16 isdeemed unnecessary.

Generally, any drafted fiber web is thicker longitudinally of itscentral portion than it is at its outer edges. This results in the webgradually increasing in width when it is being pulled from deliveryrolls 34, 34 between the primary calender rolls 120, 121 (FIGURE 4) andwhile the webs are being advanced by the conveyor means 12, 14. I havediscovered that, owing to the fact that synthetic fibers have slicker orsmoother and more slippery surfaces than natural fibers, such as cottonfibers, synthetic fiber webs spread laterally when being pulled, to agreater extent than cotton webs. Therefore, when blending synthetic andcotton fibers according to this invention, the slivers S may be soarranged upon entering the respective primary drafting units I-1V thatany synthetic fiber web or webs emerging therefrom are compensativelynarrower than any cotton web or webs emerging therefrom so that, by thetime that the composite web W formed therefrom reaches the secondarydrafting unit V, the synthetic fiber web or webs will have increased inwidth to a greater extent that the natural fiber web or webs so that allthe webs of the composite web W5 will be of substantially the samewidth, thus further contributing to uniformity of the blend.

In accordance with this invention, it can be appreciated that eachprimary drafting unit (1) is capable of drafting textile fibers of adifferent type (different kind and/or average staple length) than thatof the fibers being drafted by the other primary drafting units, (2) iscapable of applying a different amount of draft to corresponding fibersthan that applied by the other primary drafting units, and (3) maydeliver the corresponding primary web therefrom at substantially thesame speed as that at which the primary webs are delivered from theother primary drafting units and in accordance with the speed at whichthe webs are to be drawn into the secondary unit V.

Even though the bottom delivery rolls 34' of all the primary draftingunits I-IV are driven by the jack shaft 50 and may be of the samediameter, and the fibers being drafted by any one of the primary unitsmay slip relative to corresponding drafting rolls to a greater or lesserdegree than the fibers being drafted by another or others of the primaryunits, it should be noted that the change gears 53 provide means foradjusting the speed of each pair of delivery rolls so the delivery speedof all the primary webs may be substantially the same, thus providing abasis for determining the rate of travel of each primary web in itscourse to belt conveyor 12. Such changes in the speed of the deliveryrolls are automatically reflected in the speed of all the rolls of therespective primary drafting units without changing change gears 80.

The primary calender rolls 120, 121 serve the function of impartingadded crimp to each primary web when fluted delivery rolls are used orimpart initial crimp when composition top delivery rolls are used at thedrafting units LIV. More importantly, the primary calender rolls 120,121 provide means for facilitating proper tension draft for each one ofthe different types of webs emerging from the primary drafting units,while providing for the proper rate of feed of each one of the webs ontoprimary conveyor 12. The latter function of fluted calender rolls 120,121 may be appreciated by comparison of the action of the flutedcalender rolls upon two different types of webs; namely, a synthetic weband a cotton web, both of the same weight and emerging at about the samelinear speed from delivery rolls 34, 34 of different primary draftingunits.

By proper selection of gears 133, 134 (FIGURE 2) optimum surface speedof all calender rolls (about equal to that of delivery rolls 34, 34')may be obtained. The tension draft in each primary web must be held to aminimum, but must be sufficient to ensure proper conveyance of each webto the conveyor 12. If the tension draft is too high, the primary webmay be subjected to undesirable false draft, or it may be pulled apart,or holes may be formed therein, as it is being pulled around therespective curved guide plate 11. However, due to differences incohesiveness of synthetic and cotton fibers, a synthetic fiber web maytend to sag more than a cotton fiber web. Consequently, with the twowebs emerging from delivery rolls 34, 34' at about the same linearspeed, the rolls 120, 121 for the synthetic web would have to be indeeper intermeshing relationship than the fluted calender rolls for thecotton web so as to advance the synthetic web faster than the cottonweb.

Although this results in a greater length of the synthetic web emergingfrom corresponding fluted calender rolls 120, 121 per unit of time thanthat of the cotton web, the crimping effect of the fluted calender rollscauses both types of webs to emerge from the respective pairs ofcalender rolls in somewhat corrugated or undulated form, and the linearspeed of the upper reach of conveyor 12 is such as to impart a smallamount of tension to the webs as they are deposited and/or superimposedthereon. Elasticity is imparted to the primary webs by virtue of thecrimp imparted thereto by the fluted calender rolls 120, 121.

Thus, the pull of the conveyor acting on the corrugated synthetic andcotton webs removes only a relatively small amount of the undulations orcrimp from the faster moving synthetic web as compared to the amountremoved from the slower moving cotton web to avoid excessiveaccumulation or pile-up of the faster moving web on conveyor 12 and toensure proper successive superimposing or stacking of the differenttypes of webs on conveyor 12.

In the event of the synthetic web being delivered to conveyor 12 so muchfaster than the cotton web that the weight per unit length of thesynthetic web layer of the composite web W5 is too great with respect tothe cotton web layer, the delivery speed of the synthetic web atcorresponding delivery rolls 34, 34' may be reduced by use ofappropriate gears 53. or preferablv bv increasing the draft of thecorresponding rimary drafting unit, so the weight of the synthetic webapproaching corresponding calender rolls 120, 121 will have been reducedcompensatively.

Another important feature of the instant invention is that the compositeweb W5 formed by superimposing the plurality of primary webs =W1-W4passes directly from the primary units into the secondary drafting unitV which drafts and reduces the composite web to the final desired weightper unit length, either in the form of a web which may be rolled up orwhich is condensed into a final sliver and coiled into a can for furtherprocessing. The superimposing of primary webs, wherein one one or moreof the webs may be formed of a different type of fibers than the otherwebs, eflects a uniform distribution of the fibers of each webthroughout the width of the composite web and the drafting of thecomposite web through the secondary drafting unit blends andintersperses the various types of fibers with each other in a homogenousmanner to produce a thorough blending of the various fibers and a highlyuniform Weight of the fibrous material issuing from the secondarydrafting unit.

As an example of one type of blend of fibers which may be obtainedutilizing the system of the present invention, it may be assumed that asecondary sliver S weighing 60 grains per yard is to be obtained having20% 20% combed cotton fibers of about one one-eighth inch combed cottonfibers of about one and one-eighth inch average staple length, 30% Orlonfibers of about one and nine-sixteenths inches average staple length,and 40% Acrilan fibers having three inches average staple lengththerein. It may be assumed further that the slivers S fed into theprimary units each weigh 60 grains per yard, with all the slivers Sexcept the combed cotton slivers being card slivers. Although there arevarious ways in which the various types of slivers may be arranged inthe primary drafting units I-IV to obtain the desired blended sliver Stherefrom, one example as to how the slivers may be arranged will now begiven.

In setting up the apparatus, thirteen ends of card slivers of Acrilanfibers having three inches average staple length may be directed fromseparate cans C into metallic roll primary drafting unit I; ten ends ofOrlon fibers having an average staple length of two inches may bedirected from separate cans into metallic roll primary drafting unit II;five ends of Dacron fibers having two inches average staple length maybe directed into cushion roll primary drafting unit III; and eight endsof combed cotton fibers having one and one-eighth inches average staplelength may be directed into cushion roll primary drafting unit IV. Thetotal draft imparted to the fibers at the primary drafting units I-Vwould be 4.07; 4.16; 6.25 and 5, respectively. Thus, the primary websWl-W4 is suing from the drafting units I-IV would weigh about 192, 144,48 and 96 grains per yard, respectively, and the composite web W5 formedthereform thus would weigh about 480 grains per yard. The 480 grain-peryard composite web W5 would then be subjected to a draft of 8 as it ispassed through secondary drafting unit V to form the blended sliver Sweighing 60 grains per yard.

It will be noted that primary units I, II of this example are of themetallic roll type, as is desirable in producing the heavier webs ofsynthetic fibers. 0n the other hand, primary units II, III of thisexample are of the cushion roll type, as is desirable in producing thevery light (48 grains per yard) Dacron web and the highly parallelizedcombed cotton web.

It can be appreciated that the delivery speed of and amount of draftimparted to the fibers by the secondary drafting unit V aresubstantially greater than that of each primary drafting unit. Also,since the composite web is quite heavy and is formed largely fromsynthetic fibers, the secondary unit preferably is of the metallic rolltype.

Heretofore, and prior to the development of the system disclosed in mysaid copending application, the only method I am aware of by whichdifferent types of slivers could be blended in accurate proportions toobtain blends having a wide variance in the components thereof, such asthat described, has been to produce slivers of different weights perunit length and then draft several such different types of sliversthrough a common drafting unit. Even then, many proportions of differenttypes of fibers could not be obtained. Obviously, variation in the sizeof slivers has undesirably reduced the production capabilities of one ormore sliver-producing machines in the mill, such as carding machines. Inproducing a 60 grainper-yard blended sliver of the type mentioned in theforegoing example, but practicing the prior art method, as many as fouror more different sizes of slivers varying from about 44 to 60 grainsper yard may be required. Also, the various types of fibers would not bedistributed, intermixed or drafted with the uniformity or efficiencyobtainable according to the instant method where the blending is by thinwebs instead of slivers.

It is important to note that the primary webs Wl-W4 are compacted andcrimped individually by the fluted calender rolls 120, 121 associatedwith the primary drafting units to lend tensile strength thereto toassist in preventing rupture of the thin primary webs as they aresuperimposed, and to effect an efficient transition of the webs to theconveyor means. A further compacting of the webs occurs at the secondarycalendering device 16 which not only lends tensile strength to compositeweb W5, but also intermixes the fibers of adjacent superimposed webs inthe composite web W5, thus further assisting in the homogenousdistribution of the various types of fibers throughout the blend.

Although the fibrous material or stock is shown in the accompanyingdrawings being directed to the primary drafting units I-IV in the formof slivers being drawn from individual cans, it is contemplated that theincoming stock may be taken from sliver lap rolls or ribbon lap rolls.However, since it is necessary that all the fibers are withdrawn fromany one sliver lap roll or ribbon lap roll at a given speed, theenlarged inner portions of those bearings 36 (FIGURE 6) associated withthe feed rolls 31, 31' of any primaly drafting units receiving stockfrom a sliver lap roll or ribbon lap roll would have to be of suchdiameter that they would remain in engagement with the enlarged portionsof the corresponding bottom feed roll bearings 36' at all times duringoperation of a corresponding primary drafting unit or units, since avariation in the rate of feed of various portions of the webs comingfrom the ribbon lap rolls or sliver lap rolls to a particular drawingframe could not be tolerated.

In the drawings and specification there have been set forth preferredembodiments of the invention and although specific terms are employed,they are used in a generic and descriptive sense only and not forpurpose of limitation, the scope of the invention being defined in theclaims.

Iclaim:

1. A drafting system for blending a plurality of masses of textilestaple fibers comprising a row of primary drafting units arranged toproduce simultaneously from respective masses respective fibrous webs;each drafting unit comprising a series of drafting rolls including afront pair of drafting rolls; a common processing unit adjacent said rowof drafting units; means for arranging the webs emerging from saiddrafting units in superimposed relationship and for directing thesuperimposed webs to said common processing unit and comprising endlessconveyor means extending along said row of drafting units to said commonprocessing unit and respective fluted calender roll means operativelyassociated with each drafting unit and cooperating with said conveyormeans for directing the webs onto the conveyor means in superimposedrela tionship; and drive means connected to said drafting units, saidconveyor means, said calender roll means and said common processingunit, said drive means including transmission means-connected to eachdrafting unit and controlling the speed of rotation of the frontdrafting rolls of the drafting units independently of each other andindependently of the speed of said common processing unit.

2. A structure according to claim 1 wherein said common processing unitis a secondary drafting unit, and a pair of driven calender rolls arepositioned adjacent said secondary drafting unit for compacting all ofsaid superimposed webs before their entry into said secondary draftingunit.

3. A structure according to claim 1 in which said means for arrangingthe webs in superimposed relationship further comprises a curved slidemember situated to support and guide the web from each primary draftingunit downwardly to a point closely spaced above said conveyor means.

4. A drafting system for blending a plurality of masses of textilestaple fibers comprising a row of primary drafting units arranged toproduce simultaneously from respeE- tive masses respective fibrous webs;each drafting unit comprising a series of drafting rolls including afront pair of drafting rolls; a common processing unit adjacent 13 saidrow of drafting units, means for arranging the webs emerging from saiddrafting units in superimposed relationship and for directing thesuperimposed webs to said common processing unit; a common prime moverdrivingly connected to all said drafting units and to said commonprocessing unit for driving the same; transmission means interposed indriving connections between said prime mover and each drafting unit forcontrolling the speed of rotation of the front drafting rolls of thedrafting units independently of each other and independently of thespeed of said common processing unit; and said means for arranging thewebs comprising an endless belt conveyor extending along said row ofdrafting units, a pair of fluted intermeshing calender rolls arranged toimpart crimp to each respective web and maintain tension draft in eachrespective web in its course from each drafting unit to said beltconveyor, and means drivingly connecting said prime mover to saidcalender rolls and said belt conveyor such that the linear speed of thebelt conveyor causes the belt conveyor to pull and partially remove thecrimp from the webs in their course from the calender rolls to said beltconveyor.

References Cited UNITED STATES PATENTS 630,813 8/ 1899 Meats 19-2431,351,678 8/1920 Nuckols 19288 XR 1,994,174 3/1935 Fossel 192582,878,527 3/1959 Whitehurst 19159 3,063,101 11/1962 Andreani 19-243FOREIGN PATENTS 498,148 1/ 1939 Great Britain.

OTHER REFERENCES Saco-Lowell bulletin, 1932, September-October, p. 6.

20 DORSEY NEWTON, Primary Examiner zgxgfi UNITED STATES PATENT OFFICECERTIFICATE OF CORRECTION Patent No. 595 D t d July 29, 1969 Inventor)Joe R. Whitehurst It is certified that error appears in theabove-identified patent and that said Letters Patent are herebycorrected as shown below:

Column 3, Line '74, after the numeral "121' omit the word "The". Column5, Line 34, after "fluted" insert top--; Column 5,

Line 44, "23, 32'" should be --32, 32'-. Column 10, Line 63,

omit the first occurrence of "one". Column 11, Line 2, omit "20%";Column 11, Lines 2 and 3, after the first occurrence of "one" omit"one-eighth inch combed cotton fibers of about one"; Column 11, Line 4,after "length" insert --10% Dacron fibers of about two inches averagestaple 1ength-; Column 11, Line 27, "I-V" should be IV-; Column 11, Line31, "thereform should be --therefrom Column 12, Line 31, "purpose"should be --purposes.

SIGNED 'AND SEALED APH28B70 (SEAL) .Attest:

Attesting Officer WILLIAM E. Commissioner: 0

